During single point
diamond turning, the effects of tool feed rate on surface figure and finish of aluminium-6061
alloy are evaluated. The studies are conducted on 60 mm diameter optical flat surfaces.
Twenty-s ix specimens are diamond turned for varying tool feed rates (0.3 μm/rev to 30.0 μm/rev) keeping all the other
machining parameters constant. The aluminium surfaces thus machined, show a typical
roughness of 15 nm, and surface figure of better than a half wave peak-to-valley
(PV) for optimum tool feed rate. The tool feed rate between of 1.5-8.0 μm/rev is found to be optimum
for a given set of other machining parameters to get the acceptable surface figure
as well as roughness values. An empirical formula with best fit has been formulated
to find out the practical roughness achievable for the machining conditions under
study.